Manual Harley-Davidson J03322 (page 2 of 6) (English)

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Remove the Primary Chaincase

Follow the Service Manual PRIMARY CHAINCASE,

REMOVAL instructions to remove the cover, the primary

chain, clutch, engine compensating sprocket, chain

tensioner assembly, alternator and starter drive mechanism,

and the primary chaincase.

Remove the 5-Speed Transmission

1. Remove the locknut, lockwasher and flat washer to

separate the the shift rod from the 5-speed transmis-

sion shifter arm.

2. Remove oil hose cover and oil hoses at the crankcase.

a. Remove screws and cover.

b. Use side cutters to remove clamps on crankcase end

of oil supply, return and crankcase breather hoses.

3. See Figure 1. Locate vehicle speed sensor and remove

screw and the sensor from the existing transmission

case.

4. See Figure 2. Remove connectors from neutral switch.

5. See Figure 3. Remove the fasteners from the transmis-

sion exhaust bracket.

6. Remove the 4 bolts and washers connecting the trans-

mission to the engine.

NOTE

After removing the bolts, the transmission is unattached to

the frame or the engine and is resting on the support jack.

7. See Figure 4. From the right side,

slide the transmission

toward the rear of the motorcycle (to clear the ring dow-

els) and lift the transmission out of the frame.

Install 6-Speed Transmission

Slide the 6-speed transmission with oil pan from the right

side of the frame into position.

a. Center the the transmission rear mounts between the

rear swingarm mounts.

b. See Figure 4. Move transmission forward to engage the

2 ring dowels in the lower flange of crankcase.

2. Align the bolt holes on the transmission to the engine by

threading in and finger tightening the 4 bolts and washers.

NOTE

Use OPEN End Crowfoot (Snap-On FC018) on the upper

left and upper right transmission housing to crankcase bolts.

3. See Figure 5. Tighten the transmission bolts in a cross

pattern torque sequence:

a. 1

pass tighten to 15 ft-lbs (20.3 Nm).

b. 2

pass tighten to 30-35 ft-lbs (40.7-47.5 Nm).

4. Assemble the pivot shaft assembly (pivot shaft, locknut,

cup washer, rubber mount and outer spacer) and coat

the pivot shaft with Loctite

Anti-Seize.

2 of 6

-J03322

Figure 3. Exhaust Bracket on 5-Speed Side Door

(side cover removed)

i06771

Figure 1. Vehicle Speed Sensor

(behind engine oil fill plug/dipstick)

i06775

Figure 2. Neutral Indicator Switch Connector

i06782

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Harley-Davidson J03322 Manual

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